Cyclonic debris evacuation apparatus and method for a pump

ABSTRACT

A cyclonic debris evacuation apparatus and method for removing debris in a pumping system. The apparatus includes a valve rod, a cyclone component, cup component, ring component, and ring coupler component. The cup component is composed of a high density poly-fiber material that helps in creating a positive seal between the cup component and barrel interior during pumping operations, helping to direct solids into the cup component and thereby preventing them from travelling southward in the direction of the barrel and causing damage. The cup component can include a specialized leading edge adapted to direct solids into the cup component. The apparatus can include a carbide ring that prevents solids from traveling further down onto the pump plunger section. The carbide ring can incorporate ports that feed into a main channel flow. The apparatus can include a top plunger adapter capable of connecting with a sucker rod.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.12/785,028 titled CYCLONIC DEBRIS EVACUATION APPARATUS AND METHOD FOR APUMP filed May 21, 2010 by Michael Brent Ford that claimed priority toU.S. Provisional Application Ser. No. 61/180,676 titled CYCLONIC DEBRISEVACUATION APPARATUS AND METHOD FOR A PUMP and filed on May 22, 2009 byMichael Ford, all of which are hereby incorporated by reference in theirentirety.

TECHNICAL FIELD

The present application generally relates to fluid pumping apparatusesand systems and, more particularly, to a cyclonic debris evacuationapparatus and method that is intended to extend plunger and barrel life.

BACKGROUND OF THE INVENTION

Oil well pumping systems are well known in the art. Such systems can beused to mechanically remove oil or other fluid from beneath the earth'ssurface, particularly when the natural pressure in an oil well hasdiminished. Generally, an oil well pumping system begins with anabove-ground pumping unit, which can commonly be referred to as a“pumpjack,” “nodding donkey,” “horsehead pump,” “beam pump,” “sucker rodpump,” and the like. The pumping unit can create a reciprocating up anddown pumping action that moves the oil, or other substance being pumped,out of the ground and into a flow line, from which the oil is then takento a storage tank or other such structure.

Below the ground, a shaft is lined with piping known as “tubing.” Intothe tubing is inserted a string of sucker rods, which ultimately isindirectly coupled at its north end to the above-ground pumping unit.The string of sucker rods is ultimately indirectly coupled at its southend to a subsurface or “down-hole” pump that is located at or near thefluid in the oil well. The subsurface pump can have a number of basiccomponents, including a barrel and a plunger. The plunger can operatewithin the barrel, and the barrel, in turn, is positioned within thetubing. It is common for the barrel to include a standing valve and theplunger to include a traveling valve. The standing valve can have a balltherein, the purpose of which is to regulate the passage of oil fromdown-hole into the pump, allowing the pumped matter to be movednorthward out of the system and into the flow line, while preventing thepumped matter from dropping back southward into the hole. Oil can bepermitted to pass through the standing valve and into the pump by themovement of the ball off its seat, and oil is prevented from droppingback into the hole by the seating of the ball. North of the standingvalve, coupled to the sucker rods, can be the traveling valve. Thetraveling valve can regulate the passage of oil from within the pumpnorthward in the direction of the flow line, while preventing the pumpedoil from dropping back southward, in the direction of the standing valveand hole.

Actual movement of the pumped substance through the system will now bediscussed. Oil is typically pumped from a hole through a series ofdownstrokes and upstrokes of the pump, which motion is imparted by theabove-ground pumping unit. During the upstroke, formation pressurecauses the ball in the standing valve to move upward, allowing the oilto pass through the standing valve and into the barrel of the oil pump.This oil can be held in place between the standing valve and thetraveling valve. In the traveling valve, the ball is located in theseated position, held there by the pressure from the oil that has beenpreviously pumped.

On the downstroke, the ball in the traveling valve unseats, permittingthe oil that has passed through the standing valve to pass therethrough.Also during the downstroke, the ball in the standing valve seats,prevents pumped oil from moving back down into the hole. The processrepeats itself again and again, with oil essentially being moved instages from the hole, to above the standing valve and in the oil pump,to above the traveling valve and out of the oil pump. As the oil pumpfills, the oil passes through the pump and into the tubing. As thetubing is filled, the oil passes into the flow line, and is then takento the storage tank or other such structure.

There are a number of problems that are regularly encountered duringfluid pumping operations. Fluid that is pumped from the ground isgenerally impure, and includes solid impurities such as sand, pebbles,limestone, grit, iron sulfide, and other sediment and debris. Certainkinds of pumped fluids, such as heavy crude, tend to contain arelatively large amount of solids.

Solid impurities can be harmful to a fluid pumping apparatus and itscomponents for a number of reasons. For example, sand, pebbles,limestone, grit, iron sulfide, and other sediment and debris can becometrapped between pump components, causing damage and excessive wear,reducing effectiveness, and sometimes requiring a halt to pumpingoperations and replacement of the damaged components. These solidimpurities frequently collect and become concentrated between the barreland plunger. In particular, as the amount of space or clearance betweenthe exterior surface of the plunger and the interior surface of thebarrel in typical pump plungers and barrels can be as great as 0.01″,this permits a constant passage of fluid, including solid impurities,between the plunger exterior and the barrel interior. During fluidpumping operations, particularly when the pump plunger reciprocates, thecollection of solid impurities causes rapid wear to the pump components.Thus, the solid impurities that are contained within the fluid and thatpass through the space between the plunger and the barrel score theplunger and barrel surfaces, thereby reducing the operating life ofboth. In addition, frictional forces generated by the collections ofsolid impurities can cause excessive stress to be generated throughoutthe pump and sucker rod string, which often results in sticking of thepump, automatic shut-down of the pumping unit, or a parted sucker rodstring.

One prior art solution has been the use of plunger units having largeaccumulation areas into which the solid impurities can be collected. Theaccumulation areas in such plunger units are typically approximately 3-5feet long and are composed of metal. However, such units must bereplaced in their entirety when they sustain wear. In general, repairsto or replacement of pump components that become necessary by virtue ofthe aforementioned damage caused by solid impurities can betime-consuming and expensive.

The present application addresses these problems encountered in priorart pumping systems and provides other, related advantages.

Brief Description of the Preferred Embodiments

In accordance with one embodiment of the present application, a cyclonicdebris evacuation apparatus is provided. The cyclonic debris evacuationapparatus can include a cyclone component having at least one flute. Inaddition, the cyclonic debris evacuation apparatus can include a cupcomponent fitted over a portion of the cyclone component. The cyclonicdebris evacuation apparatus can also include a ring component connectedto the cup component fitted over a portion of the cyclone component andhaving a groove with at least one port. The cyclonic debris evacuationapparatus can include a ring coupler component connected to the ringcomponent and coupled to the cyclone component.

In accordance with another embodiment of the present application, amethod for removing a buildup of solid impurities on a barrel using acyclonic debris evacuation assembly is provided. The method can includecapturing solid impurities between a cup component of the cyclonicdebris evacuation assembly and the barrel in a groove positioned belowthe cup component. In addition, the method can include directing thesolid impurities in the groove into at least one port. The method canalso include flushing away the solid impurities.

In accordance with yet another embodiment of the present application, adebris removal apparatus is provided. The debris removal apparatus caninclude a hollow valve rod coupler component and a cup component fittedover a portion of the hollow valve rod coupler component. In addition,the debris removal apparatus can include a ring component fitted over aportion of the hollow valve rod coupler component having at least oneport. The debris removal apparatus can also include a ring couplercomponent coupled to the hollow valve rod coupler component. The debrisremoval apparatus can include a channel that extends through the hollowvalve rod coupler component and the ring coupler component and in fluidcommunication with the at least one port.

BRIEF DESCRIPTION OF DRAWINGS

The novel features believed to be characteristic of the application areset forth in the appended claims. In the descriptions that follow, likeparts are marked throughout the specification and drawings with the samenumerals, respectively. The drawing figures are not necessarily drawn toscale and certain figures can be shown in exaggerated or generalizedform in the interest of clarity and conciseness. The application itself,however, as well as a preferred mode of use, further objectives andadvantages thereof, will be best understood by reference to thefollowing detailed description of illustrative embodiments when read inconjunction with the accompanying drawings, wherein:

FIG. 1 is a front view of an exemplary cyclonic debris evacuationapparatus, consistent with an embodiment of the present application;

FIG. 2 is a perspective view of the exemplary cyclonic debris evacuationapparatus of FIG. 1;

FIG. 3 is a cross-sectional view of the exemplary cyclonic debrisevacuation apparatus of FIG. 2, taken along line 3-3;

FIG. 4 is a perspective view of an exemplary cyclone component of thecyclonic debris evacuation apparatus of the present application;

FIG. 5 is a side view of the exemplary cyclone component of FIG. 4;

FIG. 6 is a cross-sectional view of the exemplary cyclone component ofFIG. 5, taken along line 6-6;

FIG. 7 is a perspective view of an exemplary cup component of thecyclonic debris evacuation apparatus of the present application;

FIG. 8 is a top view of the exemplary cup component of FIG. 7;

FIG. 9 is a cross-sectional view of the exemplary cup component of FIG.7, taken along line 9-9;

FIG. 10 is a perspective view of an exemplary cup component of thecyclonic debris evacuation apparatus of the present application;

FIG. 11 is a top view of the exemplary cup component of FIG. 10;

FIG. 12 is a bottom view of the exemplary cup component of FIG. 10;

FIG. 13 is a cross-sectional view of the exemplary cup component of FIG.10, taken along line 13-13;

FIG. 14 is an exploded, perspective view of an exemplary cup componentof the cyclonic debris evacuation apparatus of the present application;

FIG. 15 is a cross-sectional view of end portions of the exemplary cupcomponent of FIG. 14;

FIG. 16 is a close-up, cross-sectional view of a portion of theexemplary cup component of FIG. 14;

FIG. 17 is an exploded, cross-sectional view of the exemplary cupcomponent of FIG. 14;

FIG. 18 is a close-up, exploded view of an end portion of the exemplarycup component of FIG. 14;

FIG. 19 is a close-up view of an end portion of the exemplary cupcomponent of FIG. 14;

FIG. 20 is a perspective view of an exemplary ring component of thecyclonic debris evacuation apparatus of the present application;

FIG. 21 is a side view of the exemplary ring component of FIG. 20;

FIG. 22 is a top view of the exemplary ring component of FIG. 20;

FIG. 23 is a perspective view of an exemplary ring coupler component ofthe cyclonic debris evacuation apparatus of the present application;

FIG. 24 is a side view of the exemplary ring coupler component of FIG.23;

FIG. 25 is a top view of the exemplary ring coupler component of FIG.23;

FIG. 26 is a cross-sectional view of the exemplary ring couplercomponent of FIG. 24, taken along line 26-26;

FIG. 27 is a perspective view of an exemplary seal device to be utilizedwith a cyclonic debris evacuation apparatus, consistent with anembodiment of the present application;

FIG. 28 is a top view of the exemplary seal device of FIG. 27;

FIG. 29 is a cross-sectional view of the exemplary seal device of FIG.28, taken along line 29-29;

FIG. 30 is a perspective view of an exemplary O-ring device to beutilized with a cyclonic debris evacuation apparatus, consistent with anembodiment of the present application;

FIG. 31 is a top view of the exemplary O-ring device of FIG. 30;

FIG. 32 is a cross-sectional view of the exemplary O-ring device of FIG.31, taken along line 32-32;

FIG. 33 is a front view of an exemplary cyclonic debris evacuationapparatus, consistent with an embodiment of the present application;

FIG. 34 is a perspective view of the exemplary cyclonic debrisevacuation apparatus of FIG. 33, shown without threading at a topportion thereof;

FIG. 35 is a side view of the exemplary cyclonic debris evacuationapparatus of FIG. 33;

FIG. 36 is a cross-sectional view of the exemplary cyclonic debrisevacuation apparatus of FIG. 35, taken along line 36-36;

FIG. 37 is a perspective view of an exemplary hollow valve rod couplercomponent of the cyclonic debris evacuation apparatus of the presentapplication;

FIG. 38 is a side view of the exemplary hollow valve rod couplercomponent of FIG. 37;

FIG. 39 a cross-sectional view of the exemplary hollow valve rod couplercomponent of FIG. 38, taken along line 39-39;

FIG. 40 is a bottom view of the exemplary hollow valve rod couplercomponent of FIG. 37;

FIG. 41 is a top view of the exemplary hollow valve rod couplercomponent of FIG. 37;

FIG. 42 is a cross-sectional view of a portion of the exemplary hollowvalve rod coupler component of FIG. 38, taken along line 42-42;

FIG. 43 is a cross-sectional view of a portion of the exemplary hollowvalve rod coupler component of FIG. 38, taken along line 43-43;

FIG. 44 is a perspective view of an embodiment of a cyclone component ofthe exemplary cyclonic debris evacuation apparatus of the presentapplication;

FIG. 45 is a side view of the exemplary cyclone component of FIG. 44;

FIG. 46 is a cross-sectional view of the exemplary cyclone component ofFIG. 44;

FIG. 47 is a cross-sectional view of a portion of the exemplary cyclonecomponent of FIG. 44;

FIG. 48 is a perspective view of an exemplary ring component of thecyclonic debris evacuation apparatus of the present application;

FIG. 49 is a side view of the exemplary ring component of FIG. 48;

FIG. 50 is a top view of the exemplary ring component of FIG. 48;

FIG. 51 is a top perspective view of an exemplary cyclonic debrisevacuation apparatus having a modified ring component, consistent withan embodiment of the present application;

FIG. 52 is a side view of the exemplary cyclonic debris evacuationapparatus of FIG. 51;

FIG. 53 is a cross-section of the exemplary cyclonic debris evacuationapparatus of FIG. 52, taken along line 44-44;

FIG. 54 is an exploded view of the portion identified by circle A shownin FIG. 53;

FIG. 55 is a bottom perspective view of the exemplary modified ringcomponent, consistent with an embodiment of the present application;

FIG. 56 is a side view of the exemplary modified ring component of FIG.55;

FIG. 57 is a cross-section of the exemplary modified ring component ofFIG. 56, taken along line 45-45;

FIG. 58 is a top view of the exemplary modified ring component of FIG.56;

FIG. 59 is a cross-section of the exemplary modified ring component ofFIG. 56, taken along line 46-46;

FIG. 60 is a bottom perspective front view of an exemplary cyclonicdebris evacuation apparatus for use with a tubing pump system,consistent with an embodiment of the present application;

FIG. 61 is a top view of the exemplary cyclonic debris evacuationapparatus of FIG. 60;

FIG. 62 is a side view of the exemplary cyclonic debris evacuationapparatus of FIG. 60; and

FIG. 63 is a cross-section of the exemplary cyclonic debris evacuationapparatus of FIG. 62, taken along line 47-47.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The foregoing description is provided to enable any person skilled inthe relevant art to practice the various embodiments described herein.Various modifications to these embodiments will be readily apparent tothose skilled in the relevant art, and generic principles defined hereincan be applied to other embodiments. Thus, the claims are not intendedto be limited to the embodiments shown and described herein, but are tobe accorded the full scope consistent with the language of the claims,wherein reference to an element in the singular is not intended to mean“one and only one” unless specifically stated, but rather “one or more.”All structural and functional equivalents to the elements of the variousembodiments described throughout this disclosure that are known or latercome to be known to those of ordinary skill in the relevant art areexpressly incorporated herein by reference and intended to beencompassed by the claims. Moreover, nothing disclosed herein isintended to be dedicated to the public regardless of whether suchdisclosure is explicitly recited in the claims.

The present application generally relates to fluid pumps and associatedsystems and, more particularly, to a cyclonic debris evacuationapparatus and method that is intended to extend plunger and barrel life.In one illustrative embodiment, a cyclonic debris evacuation apparatusand method for dispersing debris in a pumping system that forms betweenthe plunger exterior and barrel interior is provided. The apparatus canbe configured for use with a valve rod and have a cyclone component, cupcomponent, ring component, and ring coupler component. The apparatus canalso be configured for use with a hollow valve rod and have a hollowvalve rod coupler component, cup component, ring component, and ringcoupler component.

The cup component can be composed of a high density poly-fiber materialthat helps in creating a positive seal between the cup component andbarrel interior during pumping operations, helping to direct solids intothe cup component and thereby preventing them from travelling southwardin the direction of the barrel and causing damage. The cup component canalso include a specialized leading edge adapted to direct solids intothe cup component. Interior to the cyclonic debris evacuation apparatus,entering debris can become mixed with pumped fluid, and can be drawn outof the pumping system with the pumped fluid. The pumped fluid passingthrough the cyclonic debris evacuation apparatus can be caused to rotateby a radial design of flutes included on the cyclone component or anangled design of openings included on the hollow valve rod couplercomponent.

To further prevent solids from traveling down the pump plunger, thecyclonic debris evacuation apparatus can incorporate a groove to assistwith removal of the debris. The grove can be tapered to capture solidsbetween the barrel and the cup component of the cyclonic debrisevacuation apparatus. With this improvement, the solids are preventedfrom moving back and forth on the outer diameter of the cup componentreducing or eliminating barrel and plunger wear. The groove can divertthe solids away from the barrel wall and into a channel cut threehundred and sixty (360) degrees around the shaft of the apparatus. Theapparatus can be configured for which three (3) angle ports allow liquidto flow into the interior section of the main body of the apparatus. Thesolids can be swept away into the flow keeping the cup and barrel andplunger from additional wear.

Typically the cyclonic debris evacuation apparatus can be adapted toeach pump design that is currently being utilized in the production ofcrude oil. In a further illustrative embodiment, the apparatus canincorporate a top plunger adapter for tubing pump designs known to thoseskilled in the relevant art. The adapter can be coupled to a sucker rodconnector. Details of the embodiments of the present application willnow be described.

Referring first to FIGS. 1-3, a cyclonic debris evacuation apparatus 10consistent with an embodiment of the present application is shown. Indescribing the structure of the cyclonic debris evacuation apparatus 10and its operation, the terms “north” and “south” are utilized. The term“north” is intended to refer to that end of the pumping system that ismore proximate the pumping unit, while the term “south” is intended torefer to that end of the system that is more distal the pumping unit, or“down hole.” In this embodiment, the cyclonic debris evacuationapparatus 10 is configured for use with a pumping system employing avalve rod.

Beginning from the north end, the main components of this embodiment ofthe cyclonic debris evacuation apparatus 10, which has a substantiallycylindrical external configuration, include the following: (a) a cyclonecomponent 12, (b) a cup component 14, (c) a ring component 16, and (d) aring coupler component 18. The overall length of the cyclonic debrisevacuation apparatus 10 can range from approximately one foot to sixfeet or more. However, it should be clearly understood that substantialbenefit could be derived from a cyclonic debris evacuation apparatus 10having a length that deviates from these dimensions, even substantially,in either direction. For certain embodiments, it can be desired toextend the overall length of the cyclonic debris evacuation apparatus 10by providing more than one coupler pieces, such as the ring couplercomponent 18 or the like, which can be adapted to be coupled togetherend-to-end. The cyclonic debris evacuation apparatus 10 is adapted to becoupled, at a northern-most portion thereof, to a sucker rod or valverod, and at a southern-most portion thereof, to a pump plunger, asfurther discussed below.

Referring to FIGS. 4-6, the cyclone component 12 will be described. Inthis embodiment, the cyclone component 12 is a one-piece structurecomprising a substantially elongated member having a north end 20, southend 22, head 26, neck 27, and body 28 having a plurality of flutes 29.An opening 24 in the cyclone component 12 proximate its north end 20 isadapted to receive a southern portion of a sucker rod or valve rod.Threading 21 is included in this embodiment for purposes of coupling thecyclone component 12 to the sucker rod or valve rod. In this embodiment,the threading 21 is positioned at a southern portion of the opening 24,with a northern portion of opening 24 being unthreaded. The unthreadedarea of opening 24 acts as an additional support area for a valve rod.The neck 27, in this embodiment, has an overall outer diameter that isslightly less than the outer diameter of the head 26. The neck 27extends from a southern portion of the head 26 to a northern portion ofthe body 28. South of the neck 27 is the body 28, which includes theplurality of flutes 29. In this embodiment, three flutes 29 are includedin the body 28. However, it can be desired to configure a cyclonecomponent 12 having more than three or less than three flutes 29. In oneembodiment, the flutes 29 are radial. In this way, the flutes 29 assistin facilitating the rotation of fluid with solids during pumpingoperations and enable the solids to be suspended in an orbital rotationfor a longer duration during pumping operations, compared with prior artpumping systems. The flutes 29, as seen in this embodiment, extend on anangle from a southern to a northern portion of the body 28. The flutes29 are open so that fluids and solids can pass therethrough duringpumping operations, eventually continuing northward through the pumpbarrel. The flutes 29 are substantially elongated, but can be configuredin other ways, as desired. Preferably, the flutes 29 taper inwardly asthey rotate downwardly (southwardly), helping to direct solid impuritiestoward an interior portion of the flutes 29, and preventing them fromrolling outward from the flutes 29 as they move in a downward direction.Solid impurities that do reach a bottom portion of the flutes 29 areheld against an outer wall of the flutes 29 as they settle downward.Preferably, a bottom portion of the flutes 29 tapers inwardly, and awayfrom a main horizontal plane of the cyclone component 12, therebyguiding solid impurities into the openings of the flutes 29, allowingthem to settle downward in the direction of the pump plunger, andhelping to prevent solid impurities from accumulating on the barrel andcausing damage to the barrel. In this embodiment, the flutes 29 arespaced equidistant from each other. The flutes 29 communicate with achannel 25 positioned proximate the south end 22 of the cyclonecomponent 12.

Grooves 62 and 64 are positioned south of the flutes 29 on the cyclonecomponent 12. In this embodiment, one groove 62 and two grooves 64 areutilized, but it should be noted that it would be possible to vary thenumber of grooves 62 and 64, as desired. Grooves 62 and 64 are eachadapted to receive an O-ring device 60 (as shown in FIGS. 30-32). AnO-ring device 60 positioned in groove 62 can be useful for helping tosecure and align the cup component 14 in position over the cyclonecomponent 12. An O-ring device 60 (or devices 60) positioned in grooves64 can be useful for helping to secure and align the ring component 16in position over the cyclone component 12.

Preferably, the south end 22 of the cyclone component 12 includes athreaded region 23, such that the cyclone component 12 can be coupled tothe ring coupler component 18, as further discussed below.

The cyclone component 12 is preferably adapted to be fitted in the cupcomponent 14, as further discussed below. In this embodiment, when thecyclone component 12 is positioned in the cup component 14, the head 26and a portion of the neck 27 protrude from a northern portion of the cupcomponent 14, while threaded region 23 is exposed below a southernportion of the cup component 14. In a preferred embodiment, when anO-ring device 60 is positioned in groove 62, the cup component 14 can bepushed into position over the cyclone component 12. The O-ring device 60can help to align the cup component 14 over the cyclone component 12, sothat the cyclone component 12 is substantially centered within the cupcomponent 14. In another embodiment, the cyclone component 12 caninclude threading north of its south end 22, such that the cyclonecomponent 12 can be coupled to the cup component 14, as furtherdiscussed below. Preferably, the cyclone component 12 is composed of ahardened material, such as carbide, an alloy or some other suitablematerial.

Referring now to FIGS. 44-47, another embodiment of a cyclone component,hereinafter “cyclone component 12A,” is shown. The cyclone component 12Acan be used as an alternative to the cyclone component 12 and issomewhat similar to the cyclone component 12, but includes an additionalfeature of a head 26A having a plurality of flutes 29B. This featurehelps in strengthening the cyclone component 12A. In this embodiment,the cyclone component 12A is a one-piece structure comprising asubstantially elongated member having a north end 20A, south end 22A,head 26A, neck 27A, and body 28A having a plurality of flutes 29A. Anopening 24A (shown in FIG. 46) in the cyclone component 12A proximateits north end 20A is adapted to receive a southern portion of a suckerrod or valve rod. Threading 21A (shown in FIG. 46) is included in thisembodiment for purposes of coupling the cyclone component 12A to thesucker rod or valve rod. In this embodiment, the threading 21A ispositioned at a southern portion of the opening 24A, with a northernportion of opening 24A being unthreaded. The unthreaded area of opening24A acts an additional support area for a valve rod.

In this embodiment, the head 26A includes three flutes 29B. However, itcan be desired to configure a cyclone component 12A having more thanthree or less than three flutes 29B. As shown in this embodiment, thehead 26A and plurality of flutes 29B extend north of threading 21A. Inone embodiment, the flutes 29B are radial. In this way, the flutes 29Bassist in facilitating the rotation of fluid with solids during pumpingoperations and enable the solids to be suspended in an orbital rotationfor a longer duration during pumping operations, compared with prior artpumping systems. The flutes 29B, as seen in this embodiment, extend onan angle from a southern portion to a northern portion of the head 26A.The flutes 29B are open so that fluids and solids can pass therethroughduring pumping operations, eventually continuing northward through thepump barrel. The flutes 29B are substantially elongated, but can beconfigured in other ways, as desired. Preferably, the flutes 29B taperinwardly as they rotate downwardly (southwardly), helping to directsolid impurities toward an interior portion of the flutes 29B, andpreventing them from rolling outward from the flutes 29B as they move ina downward direction. Solid impurities that do reach a bottom portion ofthe flutes 29B are held against an outer wall of the flutes 29B as theysettle downward. Preferably, a bottom portion of the flutes 29B tapersinwardly, and away from a main horizontal plane of the cyclone component12A, thereby guiding solid impurities into the openings of the flutes29B, allowing them to settle downward in the direction of the pumpplunger, and helping to prevent solid impurities from accumulating onthe barrel and causing damage to the barrel. Overall, the design of theflutes 29B helps in directing solid impurities toward a central interiorportion of the cyclone component 12A, thereby helping to direct suchsolid impurities away from a leading edge of the cup component 14, 14A,or 50, as referred to below. This helps to prevent premature failure ofthe cup component 14, 14A, or 50 by preventing solid impurities fromfilling the cup component 14, 14A or 50 prematurely. In this embodiment,the flutes 29B are spaced equidistant from each other.

The neck 27A, in this embodiment, has an overall outer diameter that isslightly less than the outer diameter of the head 26A. The neck 27Aextends from a southern portion of the head 26A to a northern portion ofthe body 28A. South of the neck 27A is the body 28A, which includes theplurality of flutes 29A. In this embodiment, three flutes 29A areincluded in the body 28A. However, it can be desired to configure acyclone component 12A having more than three or less than three flutes29A. In one embodiment, the flutes 29A are radial. In this way, theflutes 29A assist in facilitating the rotation of fluid with solidsduring pumping operations and enable the solids to be suspended in anorbital rotation for a longer duration during pumping operations,compared with prior art pumping systems. The flutes 29A, as seen in thisembodiment, extend on an angle from a southern to a northern portion ofthe body 28A. The flutes 29A are open so that fluids and solids can passtherethrough during pumping operations, eventually continuing northwardthrough the pump barrel. The flutes 29A are substantially elongated, butcan be configured in other ways, as desired. Preferably, the flutes 29Ataper inwardly as they rotate downwardly (southwardly), helping todirect solid impurities toward an interior portion of the flutes 29A,and preventing them from rolling outward from the flutes 29A as theymove in a downward direction. Solid impurities that do reach a bottomportion of the flutes 29A are held against an outer wall of the flutes29A as they settle downward. Preferably, a bottom portion of the flutes29A tapers inwardly, and away from a main horizontal plane of thecyclone component 12A, thereby guiding solid impurities into theopenings of the flutes 29A, allowing them to settle downward in thedirection of the pump plunger, and helping to prevent solid impuritiesfrom accumulating on the barrel and causing damage to the barrel. Inthis embodiment, the flutes 29A are spaced equidistant from each other.The flutes 29A communicate with a channel 25A (shown in FIGS. 46 AND 47)positioned proximate the south end 22A of the cyclone component 12A.

Grooves 62A and 64A are positioned south of the flutes 29A on thecyclone component 12A. In this embodiment, one groove 62A and twogrooves 64A are utilized, but it should be noted that it would bepossible to vary the number of grooves 62A and 64A, as desired. Grooves62A and 64A are each adapted to receive an O-ring device 60 (as shown inFIGS. 30-32). An O-ring device 60 positioned in groove 62A can be usefulfor helping to secure and align the cup component 14 in position overthe cyclone component 12A. An O-ring device 60 (or devices 60)positioned in grooves 64 can be useful for helping to secure and alignthe ring component 16 in position over the cyclone component 12A.

While in this embodiment the south end 22A of the cyclone component 12Ais shown without threading, the south end 22A can include a threadedregion similar to threaded region 23 of cyclone component 12, such thatthe cyclone component 12A can be coupled to the ring coupler component18, as further discussed below.

The cyclone component 12A is preferably adapted to be fitted in the cupcomponent 14, as further discussed below. In a preferred embodiment,when an O-ring device 60 is positioned in groove 62A, the cup component14 can be pushed into position over the cyclone component 12A. TheO-ring device 60 will help to align the cup component 14 over thecyclone component 12A, so that the cyclone component 12A issubstantially centered within the cup component 14. In anotherembodiment, the cyclone component 12A can include threading north of itssouth end 22A, such that the cyclone component 12A can be coupled to thecup component 14, as further discussed below. Preferably, the cyclonecomponent 12A is composed of a hardened material, such as carbide, analloy or some other suitable material.

Turning now to FIGS. 10-13, the cup component 14 will be described. Thecup component 14 comprises an elongated, substantially tubular memberhaving a north end 30, a south end 32 and a longitudinal channel 34running therethrough. The cup component 14 is adapted to receive and fitover a portion of the cyclone component 12 (as seen in FIGS. 1-3).Preferably, the north end 30 of the cup component 14 tapers inward (asshown in FIG. 13, for example), which helps in directing solidimpurities into the interior diameter of the cup component 14. In thisembodiment, a first segment 36 of the channel 34 proximate the south end32 has an interior diameter that is less than the interior diameter ofthe channel 34 overall. In this way, when the cup component 14 is fittedover the cyclone component 12, the cup component 14 can be firmlysecured in place. As shown in this embodiment, a second segment 38 ofthe channel 34 can be angled toward the segment 36, such that anorthern-most portion of the segment 38 has an interior diametercorresponding to the interior diameter of the channel 34 overall, whilea southern-most portion of the segment 38 has an interior diametercorresponding to the interior diameter of the segment 36. In anotherembodiment, it can be desired to configure a cup component 14 having aconsistent interior diameter from the north end 30 to the south end 32.

In a preferred embodiment, the cup component 14 is comprised of a highdensity poly-fiber material. The high density poly-fiber materialnaturally has some flexibility that provides unique advantages. Forexample, when the pump is on an upstroke, the high density poly-fibermaterial expands, which permits a positive seal to be created betweenthe cup component 14 and pump barrel. This positive seal helps toprevent solid impurities from sliding between the cup component 14 andpump barrel interior. Further, the high density poly-fiber material ofthe cup component 14 can grip to an O-ring device 60 positioned ingroove 62, thereby helping to securely couple the cup component 14 inplace over the cyclone component 12. In this way, the cup component 14can be “floating” and capable of self-adjusting and becomingsubstantially centered over the cyclone component 12 and, in turn,substantially centered when positioned at various heights within a pumpbarrel, as would occur during pumping operations.

In another embodiment, the cup component 14 can include threading thatis opposite threading on the cyclone component 12 such that the cupcomponent 14 and cyclone component 12 can be coupled together.

Referring now to FIGS. 7-9, another embodiment of a cup component,hereinafter “cup component 14A,” is shown. The cup component 14A issimilar to the cup component 14. The cup component 14A comprises anelongated, substantially tubular member having a north end 30A, a southend 32A and a longitudinal channel 34A running therethrough. The cupcomponent 14A is adapted to receive and fit over a portion of thecyclone component 12. Preferably, the north end 30A of the cup component14A tapers inward (as shown in FIG. 9, for example), which helps indirecting solid impurities into the interior diameter of the cupcomponent 14A. In this embodiment, a first segment 36A of the channel34A proximate the south end 32A has an interior diameter that is lessthan the interior diameter of the channel 34A overall. In this way, whenthe cup component 14A is fitted over the cyclone component 12, the cupcomponent 14A can be firmly secured in place. In particular, an interiorportion of the cup component 14A can grip to an O-ring device 60positioned in groove 62, thereby helping to securely couple the cupcomponent 14A in place over the cyclone component 12. In this way, thecup component 14A can be “floating” and capable of self-adjusting andbecoming substantially centered over the cyclone component 12 and, inturn, substantially centered when positioned at various heights within apump barrel, as would occur during pumping operations.

As shown in this embodiment, a second segment 38A of the channel 34A canbe angled toward the segment 36A, such that a northern-most portion ofthe segment 38A has an interior diameter corresponding to the interiordiameter of the channel 34A overall, while a southern-most portion ofthe segment 38A has an interior diameter corresponding to the interiordiameter of the segment 36A. In another embodiment, it can be desired toconfigure a cup component 14A having a consistent interior diameter fromthe north end 30A to the south end 32A. Preferably, the cup component14A is composed of a hardened material, such as carbide, an alloy orsome other suitable material.

In another embodiment, the cup component 14A can include threading thatis opposite threading on the cyclone component 12 such that the cupcomponent 14A and cyclone component 12 can be coupled together.

Turning now to FIGS. 14-19, a further embodiment of the cup component,hereinafter “cup component 50,” is shown. The cup component 50 can beutilized with the cyclonic debris evacuation device 10 as an alternativeto the cup component 14 or cup component 14A. As seen in thisembodiment, the cup component 50 includes two basic parts: a cup body 52and a wear region 54. The wear region 54 is adapted to be removablycoupled to the cup body 52 to form the cup component 50. In thisembodiment, the wear region 54 includes a notched region 56 adapted tocorrespond to a notched region 58 positioned on the cup body 52, asshown in FIG. 17. In this way, the wear region 54 can be secured to thecup body 52 by inserting the wear region 54 into the cup body 52 andallowing the wear region 54 to snap and lock into place, as indicated bythe arrows in FIG. 17. In another embodiment, threading can be providedon the cup body 52 and wear region 54 that would correspond with oneanother, to permit the wear region 54 to be screwed into place in thecup body 52.

In this embodiment, the wear region 54 includes a leading edge 54A. Whenthe cup component 50 is positioned on the cyclonic debris evacuationapparatus 10, preferably, the leading edge 54A faces northward. In oneembodiment, the leading edge 54A tapers inward (as shown in FIGS. 15-17,for example), which helps in directing solid impurities into theinterior diameter of the cup component 50. Preferably, the leading edge54A is composed of a durable elastic or composite type of material. Forexample, with regard to elastic material, the leading edge 54A can becomposed of various rubber compounds, such as neoprene(polychloroprene), nitrile (BUNA-N), urethane, fluoroelastomer (viton),and the like. As another example, with regard to composite material, theleading edge 54A can be composed of various materials, such aspoly-fiber, rubber-fiber, carbon-fiber, and the like. Preferably, thematerial utilized for the leading edge 54A of the wear region 54 wouldbe of a type that is capable of withstanding frictional forces and isabrasive-resistant.

With such an elastic or composite type of material utilized for theleading edge 54A, a positive seal and wear area can be formed between anexterior portion of the leading edge 54A and an interior portion of thepump barrel that will prevent solid impurities from passing southward tothe pump plunger and thereby causing damage. While the wear region 54would eventually need to be replaced at some intervals when the pumpunit is repaired, the cup body 52 of the cup component 50 would not needto be replaced as frequently as the wear region 54. The wear region 54is preferably comprised of a durable elastic or composite material. Thewear region 54 can include notches 59, as seen in this embodiment.Notches 59 can help facilitate ease of placement of wear region 54 intothe cup body 52. In this embodiment, four notches 59 are shown and areplaced equidistant from each other. It can be desired to include morethan four or less than four notches 59 on wear region 54.

With regard to the cup body 52, it can be composed of a metal or sometype of composite material, such as poly-fiber, rubber-fiber,carbon-fiber, and the like. An advantage to employing composite materialis that it allows for more flexibility and a tighter seal as compared tometal. In this regard, a high density poly-fiber material, for example,naturally has some flexibility that provides unique advantages, asdiscussed above.

With reference now to FIGS. 48-50, an alternative cup component 14B isshown. The cup component 14B includes a groove 150 that separates twoportions of the cup component 14B. In a preferred embodiment, the cupcomponent 14B can be made of a high density poly-fiber material. Thehigh density poly-fiber material can naturally have some flexibilitythat provides unique advantages. For example, when the pump is on anupstroke, the high density poly-fiber material expands, which permits apositive seal to be created between the cup component 14B and pumpbarrel. This positive seal can help prevent solid impurities fromsliding between the cup component 14B and pump barrel interior. Further,the high density poly-fiber material of the cup component 14B can gripto an O-ring device 60 positioned in groove 62, thereby helping tosecurely couple the cup component 14B in place over the cyclonecomponent 12. In this way, the cup component 14B can be “floating” andcapable of self-adjusting and becoming substantially centered over thecyclone component 12 and, in turn, substantially centered whenpositioned at various heights within a pump barrel, as would occurduring pumping operations.

Referring now to FIGS. 20-22, the ring component 16 will be described.The ring component 16 comprises a cylindrical unit that is adapted tofit over a southern portion of the cyclone component 12, south of thecup component 14 (as seen in FIGS. 1 and 2, for example). Preferably,the ring component 16 is composed of a hardened material, such ascarbide, an alloy, or some other suitable hardened material that iscapable of crushing any solid impurities that do pass between the cupcomponent 14 and the interior diameter of the barrel. In anotherembodiment, the ring component 16 can be coated with a material such ascarbide, nickel, an alloy, or the like. In one embodiment, the ringcomponent 16 can be comprised of carbide having a Rockwell hardness ofabout 87, but the ring component 16 could have a Rockwell hardness thatvaries from this. The ring component 16 can grip to an O-ring device 60positioned in grooves 64 of the cyclone component 12, thereby helping tosecurely couple the ring component 16 in place over the cyclonecomponent 12. In this way, the ring component 16 can be “floating” andcapable of self-adjusting and becoming substantially centered over thecyclone component 12 and, in turn, substantially centered whenpositioned at various heights within a pump barrel, as would occurduring pumping operations.

Now referring to FIGS. 51-59, an embodiment showing a modified ringcomponent 16A is provided. The ring component 16A can be a cylindricalunit that is adapted to fit over a southern portion of the cyclonecomponent 12A, south of the cup component 14 (as seen in FIG. 51, forexample). Those skilled in the relevant art will appreciate that thering component 16A can also be incorporated into other embodimentsdisclosed herein. For instance, the cyclone component 12A shown can bereplaced with the cyclone component 12 of FIGS. 1-3.

The ring component 16A can assist in keeping solids from passing twiceover the cup thereby reducing the wear and keeping the cup component 14from premature failure. Solids can generally pass the cup as it wearsand settles atop the ring component 16A. The cup component 14 can bedesigned to shear in the event solids overwhelm the cup component 14,which could cause the pump plunger to seize. The cup component 14 canallow the pumping action to continue without causing damage to the rodsor barrel/pump by shearing itself away from the main body of theapparatus 10. The sheared cup component 14 can slide up and down withthe pump action once it release or un-seizes.

The ring component 16A can be composed of a hardened materials describedabove. The modified ring component 16A can also made of differentmaterials as its purpose is no longer to crush solid impurities thatpass between the cup component 14 and the interior diameter of thebarrel. The ring component 16A can be made of carbide and be referredherein as a carbide ring. FIG. 51 depicts the cyclonic debris evacuationapparatus 10 having the cyclone component 12A removed from the cupcomponent 14 and detached from the ring coupler component 18, with thebottom portion of the cyclone component 12A showing.

The ring component 16A can grip to an O-ring device 60 positioned ingrooves 64 of the cyclone component 12A, thereby helping to securelycouple the ring component 16A in place over the cyclone component 12A.In this way, the ring component 16A can be “floating” and capable ofself-adjusting and becoming substantially centered over the cyclonecomponent 12A and, in turn, substantially centered when positioned atvarious heights within a pump barrel, as would occur during pumpingoperations.

With reference now to FIG. 52, a side view of the exemplary cyclonicdebris evacuation apparatus 10 when assembled is shown. Many of the samecomponents described above are shown therein. FIG. 53 is a cross-sectionof the exemplary cyclonic debris evacuation apparatus 10 of FIG. 52,taken along line 44-44. The cross-section shows the cyclone component12A extending past the cup component 14 and modified ring component 16Aending at the ring coupler component 18.

Turning now to FIG. 54, an exploded view of the portion identified bycircle A shown in FIG. 53 is provided. The ring component 16A can have atapered groove 162 that captures solids keeping them off the barrelwhich could cause barrel wear. The groove 162 can extend along an outerdiameter of the ring component 16A. The channel can be cut three hundredand sixty (360) degrees around the shaft of the evacuation apparatus 10.

In the groove 162, a number of holes or ports 160 can be placed therein.In one embodiment, three ports 160 can be placed within the groove 162and spaced equidistant from each other. The groove 162 can accumulatesolids gathered from the barrel wall and allow the solids to escapeinward thru the ports 160 in the ring component 16A. In one embodiment,the ports 160 are angled. Through the angled ports 160, the interiorflow section of the cyclone component 12A can be accessed. The angledports 160 can allow a venture effect that causes the solids to flowinwards into the ports 160.

After the solids enter through the ports 160, they can enter into themain flow section of the cyclone component 12A where the solids areswept away into the flow keeping the cup component 14 and barrel andplunger from additional wear. Without this improvement, typically solidswould move back and forth on the outer diameter of the cup component 14causing cup component 14, barrel, and plunger wear.

Now referring to FIG. 55, a bottom perspective view of the exemplarymodified ring component 16A is provided. The ring component 16A canincorporate a top portion 164 and a bottom portion 166 separated by thegroove 162. The top portion 164 and bottom portion 166 typicallyincorporates an outer diameter that matches that of the evacuationapparatus 10. The interior diameter of the portions 164 and 166 andgroove 162 can have a diameter such that the cyclone component 12A canfit therethrough.

While the groove 160, as illustrated, includes a narrow channel, thoseskilled in the relevant art will appreciate that the groove 160 canextend further towards the top portion 164 and/or bottom portion 166.The ports 160 can also be provided in a variety of different forms.Fewer or more ports 160 can be incorporated within the groove 160.

FIG. 56 is a side view of the exemplary modified ring component 16A ofFIG. 55. As shown and in accordance with one embodiment, the top portion164 can have a smaller outer diameter than the bottom portion 166. Byreducing the outer diameter of the top portion 164, the solids can betrapped below the cup component 14 and be captured in the ports 160 ofthe ring component 16A. From there, the solids can be swept inward tothe main flow of fluid more easily than if both the top portion 164 andbottom portion 166 had the same outer diameters.

In one embodiment, the top section 164 can taper inwards. Now referringto FIG. 57, a cross-section of the exemplary modified ring component ofFIG. 56, taken along line 45-45, is provided. The top section 164, asshown more clearly, can incorporate the tapering towards the groove 162.The tapering can allow the modified ring component 16A to collect solidsthat flow past the cup component 14.

FIG. 58 is a top view of the exemplary modified ring component 16A ofFIG. 56. The top portion 164 shown provides a circular shape allowingthe cyclone component 12A to fit through. Turning to FIG. 59, across-section of the exemplary modified ring component of FIG. 56, takenalong line 46-46 is provided. As more clearly shown, the ports 160 canallow solids to pass through the groove 162 into the channel formedwithin the ring component 16A. It should be noted that although the ringcomponents 16 and 16A are shown in the embodiments of the cyclonicdebris evacuation apparatus 10, it can be desired to have otherembodiments of the cyclonic debris evacuation apparatus 10 in which thering components 16 and 16A are omitted.

Turning now to FIGS. 23-26, the ring coupler component 18 will bedescribed. The ring coupler component 18 comprises a substantiallycylindrical device having a north end 40, south end 42, and alongitudinal channel 44 running therebetween. A first threaded region 41is included in an interior diameter portion of the ring couplercomponent 18 proximate the north end 40. The threading of the threadedregion 41 preferably corresponds to threaded region 23 on the cyclonecomponent 12. In this way, a northern portion of the ring couplercomponent 18 is adapted to be coupled to a southern portion of thecyclone component 12. While in this embodiment threading is used tocouple the ring coupler component 18 and cyclone component 12 together,it can be desired to employ other suitable coupling mechanisms.

A first shoulder 45 is positioned south of the threaded region 41. Whenthe ring coupler component 18 is coupled to the cyclone component 12,the south end 22 of the cyclone component 12 can rest against theshoulder 45. A second threaded region 43 is included in an interiordiameter portion of the ring coupler component 18 proximate the southend 42. The threading of the threaded region 43 preferably correspondsto threading on a standard pump plunger, such that a southern portion ofthe ring coupler component 18 can be coupled to the pump plunger. Whilein this embodiment threading is used for purposes of coupling the ringcoupler component 18 to a pump plunger, it can be desired to employother suitable coupling mechanisms. A second shoulder 47 is positionednorth of the threaded region 43. When the ring coupler component 18 iscoupled to a pump plunger, a north end of the pump plunger can restagainst the shoulder 47.

In this embodiment, the ring coupler component 18 includes a groove-likeportion comprising an accumulator region 46. The accumulator region 46includes a north shoulder 46A and a south shoulder 46B. Preferably, thenorth shoulder 46A and south shoulder 46B are each downwardly-tapered.Such downward tapering helps to facilitate the trapping of solidimpurities, thereby preventing them from sliding further southward inthe direction of the pump plunger. Also in this embodiment, the ringcoupler component 18 includes grooves 48 and 49. The grooves 48 and 49are positioned southward of the accumulator region 46 and are eachadapted to receive a seal 70 (shown in FIGS. 1-3 and 27-29). In thisembodiment, two grooves 48 and 49 and two seals 70 are employed.However, it would be possible to configure a ring coupler component 18having more than two or less than two grooves 48 and 49 and seals 70.The ring coupler component 18 can be composed of a hardened material,such as carbide, an alloy or some other suitable material.

With respect to the seals 70, preferably, they are composed of a durableplastic or some other suitable material capable of withstandingconditions present in typical well environments. In one embodiment, itcan be desired to utilize a pressure actuated ring seal called theDarcova XT®, sold by Darcova, Inc. The seals 70 assist in preventingsolid impurities from travelling further southward toward the pumpplunger. In this embodiment, a first seal 70, when positioned in groove49, aligns flush with the overall outer diameter of the ring couplercomponent 18. Preferably, an area of the ring coupler component 18 northof the groove 48 has in outer diameter that is slightly smaller than anoverall outer diameter of the ring coupler component 18. In this way,when a second seal 70 is positioned in groove 48, a lip 72 of the seal70 protrudes slightly from the ring coupler component 18. Preferably,the lip 72 is downwardly tapered, as shown in detail in FIG. 29. In thisway, the lip 72 is adapted to trap solid impurities, thereby helping toprevent them from sliding past seal 70 positioned in groove 48 andtravelling further southward in the direction of the pump plunger. Inparticular, the lip 72 can trap solid impurities that have slid past theaccumulator region 46.

Referring now to FIGS. 33-40, a cyclonic debris evacuation apparatus 100consistent with an embodiment of the present application is shown. Thecyclonic debris evacuation apparatus 100 is similar to the cyclonicdebris evacuation apparatus 10, but includes unique features such thatit is configured for use with a pumping system employing a hollow valverod. For individual components of the cyclonic debris evacuationapparatus 100 that are the same as components on the cyclonic debrisevacuation apparatus 10, like numbers are used.

Beginning from the north end, the main components of this embodiment ofthe cyclonic debris evacuation apparatus 100, which has a substantiallycylindrical external configuration, include the following: (a) a hollowvalve rod coupler component 112, (b) a cup component 14, (c) a ringcomponent 16, and (d) a ring coupler component 18. The overall length ofthe cyclonic debris evacuation apparatus 100 can range fromapproximately one foot to six feet or more. However, it should beclearly understood that substantial benefit could be derived from acyclonic debris evacuation apparatus 100 having a length that deviatesfrom these dimensions, even substantially, in either direction. Forcertain embodiments, it can be desired to extend the overall length ofthe cyclonic debris evacuation apparatus 100 by providing more than onecoupler pieces, such as the ring coupler component 18 or the like, whichcan be adapted to be coupled together end-to-end. The cyclonic debrisevacuation apparatus 100 is adapted to be coupled, at a northern-mostportion thereof, to a hollow valve rod, and at a southern-most portionthereof, to a pump plunger, as further discussed below.

Referring to FIGS. 37-39, the hollow valve rod coupler component 112will be described. In this embodiment, the hollow valve rod couplercomponent 112 is a one-piece structure comprising a substantiallyelongated member having a north end 114, south end 116, head 118, neck120, and base 128 having a plurality of openings 130. A channel 124 runslongitudinally through the hollow valve rod coupler component 112 and isadapted to communicate with channel 44 in the ring coupler component 18,allowing passage of fluid therethrough. The hollow valve rod couplercomponent 112 is adapted to be coupled, at its north end 114, to ahollow valve rod. External threading 126, as shown in FIG. 33, can beincluded for purposes of coupling the hollow valve rod coupler component112 to the hollow valve rod. Alternatively, threading can be included inthe interior diameter of a northern portion of the head 118, for thispurpose.

The head 118 of the hollow valve rod coupler component 112 includesgrooves 131 and 132 defining shoulders 134 and 136, respectively. Whilein this embodiment two grooves 131 and 132 are included in head 118, itcan be desired to fashion a hollow valve rod coupler component 112having more than two or less than two grooves 131 and 132. The grooves131 and 132 are each adapted to receive a seal 70 (shown in FIGS. 27-29and 33-36, for example). In this embodiment, the head 118 of the hollowvalve rod coupler component 112 further includes an accumulator region138. The accumulator region 138 includes a lip 140. Preferably, the lip140 is downwardly-tapered. Such downward tapering helps to facilitatethe trapping of solid impurities, thereby preventing them from slidingfurther southward in the direction of the pump plunger. With respect togrooves 131 and 132, these are positioned southward of the accumulatorregion 138.

With respect to the seals 70, preferably, they are composed of a durableplastic or some other suitable material capable of withstandingconditions present in typical well environments. In one embodiment, itcan be desired to utilize a pressure actuated ring seal called theDarcova XT®, sold by Darcova, Inc. The seals 70 assist in preventingsolid impurities from travelling further southward toward the pumpplunger. In this embodiment, a first seal 70, when positioned in groove132, aligns flush with an outer diameter of the head 118. Preferably, anarea of the head 118 north of the groove 131 has in outer diameter thatis slightly smaller than an outer diameter directly south of groove 131.In this way, when a second seal 70 is positioned in groove 131, a lip 72of the seal 70 protrudes slightly from the head 118. Preferably, the lip72 is downwardly tapered, as shown in detail in FIG. 29. In this way,the lip 72 is adapted to trap solid impurities, thereby helping toprevent them from sliding past seal 70 positioned in groove 131 andtravelling further southward in the direction of the pump plunger. Thehead 118 further includes a leading shoulder 138. The leading shoulder138 preferably has a downwardly tapered lip 140. In this way, the lip140 is adapted to trap solid impurities. Solid impurities that slidepast the lip 140 can be trapped by lip 72 on seal 70 positioned ingroove 131.

The neck 120, in this embodiment, has an overall outer diameter that isless than the outer diameter of a portion of the head 118 positionednorth of the neck 120. The neck 120 extends from a southern portion ofthe head 118 to a northern portion of the base 122. South of the neck120 is the base 122, which includes the plurality of openings 130. Inthis embodiment, three openings are included in the base 122. However,it can be desired to configure a hollow valve rod coupler component 112having more than three or less than three openings 130. In oneembodiment, the openings are off-set from a center of longitudinalchannel 124, as best seen in FIGS. 39 and 42. In this way, the openings130 assist in facilitating the rotation of fluid with solids duringpumping operations. Thus, as fluid enters the openings 130, the fluid iscaused to spin by the angled design of the openings 130 and is directedaway from the pump barrel as it travels northward through the pumpingsystem. In this embodiment, and as seen in FIG. 42, the openings 130extend toward longitudinal channel 124 on an angle. In this embodiment,the openings 130 are spaced equidistant from each other.

The base 122, in this embodiment, includes grooves 142 and 144, andshoulder 146, each positioned south of the openings 130 on the hollowvalve rod coupler component 112. In this embodiment, one groove 142 andtwo grooves 144 are utilized, but it should be noted that it would bepossible to vary the number of grooves 142 and 144, as desired. Thegrooves 142 and 144 are each adapted to receive an O-ring device 60 (asshown in FIGS. 30-32). An O-ring device 60 positioned in groove 142 canbe useful for helping to secure and align the cup component 14 inposition over the hollow valve rod coupler component 112. An O-ringdevice 60 (or devices 60) positioned in grooves 144 can be useful forhelping to secure and align the ring component 16 in position over thehollow valve rod coupler component 112.

Preferably, the south end 116 of the hollow valve rod coupler component112 includes a threaded region 148, such that the hollow valve rodcoupler component 112 can be coupled to the ring coupler component 18,as further discussed below.

The hollow valve rod coupler component 112 is preferably adapted to befitted in the cup component 14, as further discussed below. In thisembodiment, when the hollow valve rod coupler component 112 ispositioned in the cup component 14, the head 118 and a portion of theneck 120 protrude from a northern portion of the cup component 14, whilethreaded region 148 is exposed below a southern portion of the cupcomponent 14. In a preferred embodiment, when an O-ring device 60 ispositioned in groove 142, the cup component 14 can be pushed intoposition over the hollow valve rod coupler component 112. The O-ringdevice 60 will help to align the cup component 14 over the hollow valverod coupler component 112, so that the hollow valve rod couplercomponent 112 is substantially centered within the cup component 14. Inanother embodiment, the hollow valve rod coupler component 112 caninclude threading north of its south end 116, such that the hollow valverod coupler component 112 can be coupled to the cup component 14, asfurther discussed below. Preferably, the hollow valve rod couplercomponent 112 is composed of a hardened material, such as carbide, analloy or some other suitable material.

With respect to the cup component 14 utilized with the cyclonic debrisevacuation apparatus 100, it is the same as the cup component 14utilized with the cyclonic debris evacuation apparatus 10, previouslydiscussed in detail, above, and as shown in FIGS. 10-13. The discussionabove concerning the cup component 14 is hereby incorporated herein byreference, to the extent not repeated below. When utilized with thecyclonic debris evacuation apparatus 100, the cup component 14 isadapted to receive and fit over a portion of the hollow valve rodcoupler component 112 (as seen in FIGS. 33-36). Preferably, the northend 30 of the cup component 14 tapers inward (as shown in FIG. 13, forexample), which helps in directing solid impurities into the interiordiameter of the cup component 14. In the embodiment of the cup component14 shown in FIGS. 10-13, a first segment 36 of the channel 34 proximatethe south end 32 has an interior diameter that is less than the interiordiameter of the channel 34 overall. In this way, when the cup component14 is fitted over the hollow valve rod coupler component 112, the cupcomponent 14 can be firmly secured in place.

In a preferred embodiment, the cup component 14 is comprised of a highdensity poly-fiber material. The high density poly-fiber materialnaturally has some flexibility that provides unique advantages. Forexample, when the pump is on an upstroke, the high density poly-fibermaterial expands, which permits a positive seal to be created betweenthe cup component 14 and pump barrel. This positive seal helps toprevent solid impurities from sliding between the cup component 14 andpump barrel interior. Further, the high density poly-fiber material ofthe cup component 14 can grip to an O-ring device 60 positioned ingroove 142, thereby helping to securely couple the cup component 14 inplace over the hollow valve rod coupler component 112. In this way, thecup component 14 can be “floating” and capable of self-adjusting andbecoming substantially centered over the hollow valve rod couplercomponent 112 and, in turn, substantially centered when positioned atvarious heights within a pump barrel, as would occur during pumpingoperations.

In another embodiment, the cup component 14 can include threading thatis opposite threading on the hollow valve rod coupler component 112 suchthat the cup component 14 and hollow valve rod coupler component 112 canbe coupled together.

The cyclonic debris evacuation apparatus 100 can also be utilized withthe cup component 14A (discussed in detail above and shown in FIGS.7-9), as an alternative to cup component 14. The discussion aboveconcerning the cup component 14A is hereby incorporated herein byreference, to the extent not repeated below. The cup component 14A isadapted to receive and fit over a portion of the hollow valve rodcoupler component 112. Preferably, the north end 30A of the cupcomponent 14A tapers inward (as shown in FIG. 9, for example), whichhelps in directing solid impurities into the interior diameter of thecup component 14A. In this embodiment, a first segment 36A of thechannel 34A proximate the south end 32A has an interior diameter that isless than the interior diameter of the channel 34A overall. In this way,when the cup component 14A is fitted over the hollow valve rod couplercomponent 112, the cup component 14A can be firmly secured in place. Inparticular, an interior portion of the cup component 14A can grip to anO-ring device 60 positioned in groove 142, thereby helping to securelycouple the cup component 14A in place over the hollow valve rod couplercomponent 112. In this way, the cup component 14A can be “floating” andcapable of self-adjusting and becoming substantially centered over thehollow valve rod coupler component 112 and, in turn, substantiallycentered when positioned at various heights within a pump barrel, aswould occur during pumping operations.

In another embodiment, the cup component 14A can include threading thatis opposite threading on the hollow valve rod coupler component 112 suchthat the cup component 14A and hollow valve rod coupler component 112can be coupled together.

The cyclonic debris evacuation apparatus 100 can also be utilized withthe cup component 50 (discussed in detail above and shown in FIGS.14-19), as an alternative to cup component 14. The discussion aboveconcerning the cup component 50 is hereby incorporated herein byreference, to the extent not repeated below. When the cup component 50is positioned on the cyclonic debris evacuation apparatus 100,preferably, the leading edge 54A faces northward. In one embodiment, theleading edge 54A tapers inward (as shown in FIGS. 15-17, for example),which helps in directing solid impurities into the interior diameter ofthe cup component 50.

With respect to the ring component 16 utilized with the cyclonic debrisevacuation apparatus 100, it is the same as the ring component 16utilized with the cyclonic debris evacuation apparatus 10, previouslydiscussed in detail, above, and as shown in FIGS. 20-22. The discussionabove concerning the ring component 16 is hereby incorporated herein byreference, to the extent not repeated below. The ring component 16comprises a cylindrical unit that is adapted to fit over a southernportion of the hollow valve rod coupler component 112, south of the cupcomponent 14 (as seen in FIGS. 33-35, for example). The ring component16 can grip to an O-ring device 60 positioned in grooves 144 of thehollow valve rod coupler component 112, thereby helping to securelycouple the ring component 16 in place over the hollow valve rod couplercomponent 112. In this way, the ring component 16 can be “floating” andcapable of self-adjusting and becoming substantially centered over thehollow valve rod coupler component 112 and, in turn, substantiallycentered when positioned at various heights within a pump barrel, aswould occur during pumping operations.

It should be noted that although the ring component 16 is shown in theembodiment of the cyclonic debris evacuation apparatus 100 of FIGS.33-36, it can be desired to have other embodiments of the cyclonicdebris evacuation apparatus 100 in which the ring component 16 isomitted.

With respect to the ring coupler component 18 utilized with the cyclonicdebris evacuation apparatus 100, it is the same as the ring couplercomponent 18 utilized with the cyclonic debris evacuation apparatus 10,previously discussed in detail, above, and as shown in FIGS. 23-26. Thediscussion above concerning the ring component 16 is hereby incorporatedherein by reference, to the extent not repeated below. A first threadedregion 41 is included in an interior diameter portion of the ringcoupler component 18 proximate the north end 40. The threading of thethreaded region 41 preferably corresponds to threaded region 148 on thehollow valve rod coupler component 112. In this way, a northern portionof the ring coupler component 18 is adapted to be coupled to a southernportion of the hollow valve rod coupler component 112. While in thisembodiment threading is used to couple the ring coupler component 18 andhollow valve rod coupler component 112 together, it can be desired toemploy other suitable coupling mechanisms.

A first shoulder 45 is positioned south of the threaded region 41. Whenthe ring coupler component 18 is coupled to the hollow valve rod couplercomponent 112, the south end 116 of the hollow valve rod couplercomponent 112 can rest against the shoulder 45.

Turning now to FIGS. 60-63, an exemplary cyclonic debris evacuationapparatus 10 for use with tubing pumps, consistent with an embodiment ofthe present application, is provided. The cyclonic debris evacuationapparatus 10 is similar to those described above, but includes uniquefeatures such that it is configured for use with a tubing pump system.For similar components of the cyclonic debris evacuation apparatus 10like numbers are used.

The main components of this embodiment of the cyclonic debris evacuationapparatus 10, which has a substantially cylindrical externalconfiguration, can include the following: (a) a cyclone component 12Ahaving flutes 29A or cyclone component 12 with flutes 29 (b) a cupcomponent 14, (c) a ring component 16, and (d) a ring coupler component18. The overall length of the cyclonic debris evacuation apparatus 10can range from approximately one foot to six feet or more. The cyclonicdebris evacuation apparatus 10 is adapted to be coupled, at anorthern-most portion thereof, to a sucker rod, and at a southern-mostportion thereof, to a pump plunger.

Coupled to the top portion of the cyclonic debris evacuation apparatus10 is a top plunger adapter 170 as shown in FIG. 61. The top plungeradapter 170 can provide versatility to the cyclonic debris evacuationapparatus 10. In one embodiment, the adapter 170 can include externalthreading. The external threading can be used to connect the sucker rodto the adapter 170 for a tight fit. In one embodiment, the threading canbe located on the sucker rod. External or internal threading can beprovided on the adapter 170 to secure the sucker rod. Known to thoseskilled in the relevant art, numerous other types of locking mechanismscan be used by the adapter 170, sucker rod, or both.

FIG. 63 is a cross-section of the exemplary cyclonic debris evacuationapparatus 10 of FIG. 62, taken along line 47-47. The tubing pump designutilizes the well tubing for the barrel; therefore there is no need tohave an additional barrel. Beforehand, an insert pump and a hollow valverod were described. The insert pump included female threading 21 withthe cyclonic debris evacuation apparatus 10 that allowed a valve rod tobe attached. The hollow valve rod included the cyclonic debrisevacuation apparatus 100 with the male external threading 126 that had apathway therethrough. In the embodiment now provided, the top plungeradapter 170 includes male external threading with no pathwaytherethrough to allow a sucker rod connector to be attached. As shown,the adapter 170 is solid. This makes the top plunger adapter 170 uniquein that it can be functional on all or most types of down-hole rodpumps.

Statement of Operation

Before assembling the cyclonic debris evacuation apparatus 10 orcyclonic debris evacuation apparatus 100, it is preferred to apply anantiseize lubricant to all external threads, in order to prevent thevarious components of the cyclonic debris evacuation apparatus 10 or 100from seizing together. As an example, McMaster-Carr P/N 1820K1 SSTantiseize lubricant can be used.

In typical prior art pumping systems, when pumping operations havestopped, solid impurities naturally settle into the space between theplunger and the barrel. When the cyclonic debris evacuation apparatus 10or 100 of the present application is coupled to a pump plunger, afterpumping operations have stopped, solid impurities will settle into thecup component 14 (or 14A or 50), instead of travelling past it andaround the plunger, as is typical in standard prior art designs. Uponrestarting of the pump the preferred high density poly-fiber materialcomprising the cup component 14 will load with pressure and will expandon the upstroke, flaring outward. It will then experience little, ifany, slippage because the cup component 14 will expand against theinterior diameter of the barrel. In this way, a positive seal will becreated between the barrel and cup component 14. As a result, on theupstroke, solid impurities that would normally slip southward will beswept inward and away from the inside surface of the barrel and will beredirected to the cup component 14, where they will accumulate. Thedesign of the cyclonic debris evacuation apparatus 10 or 100hydraulically forces residual solid impurities inwardly to the interiordiameter of the plunger. As a result, stuck plungers and excessivebarrel damage and wear can be avoided.

On the downstroke, the high density poly-fiber material of the cupcomponent 14 will retract. As this occurs, the design of the flutes 29in the cyclone component 12 and the openings 130 in the hollow valve rodcoupler component 112 causes the fluid that is being pumped and anysolid impurities entrained therein to constantly rotate. This rotationpermits the pump barrel and plunger to wear more evenly, resulting inlonger pump life and a more cost efficient pump assembly. The solidimpurities that are entrained in the pumped fluid are then flushed awayand enter the produced well stream.

When the pump is not operational, the settling solid impurities areredirected into the cup component 14, through the flutes 29 of thecyclone component 12 or the openings 130 of the hollow valve rod couplercomponent 112 and inward into the interior diameter of the pump plunger.This keeps any concentration of solid impurities from accumulating andwedging between the outer diameter of the plunger and the pump barrel,thereby reducing the possibility of plunger sticking and excessivebarrel wear.

Any solids that do pass between the cup component 14 and the interiordiameter of the barrel and travel southward will come into contact withthe ring component 16. Due to the hardness of the ring component 16, anysolid impurities that do come into contact with it will be crushed. Whenthe solid impurities are crushed, the remnants thereof will pass by theplunger without damaging it.

The high density poly-fiber material of the cup component 14 willeventually experience wear as a result of use, and over time will notentrap all solid impurities. Thus, solids that escape past the cupcomponent 14 will then begin to accumulate in the accumulator region 46of the ring coupler component 18. In this way, the accumulator region 46of the ring coupler component 18 acts as a secondary containment area tohelp prevent solid impurities from travelling further southward and intothe area of the plunger.

It should be noted that the cup component 14, ring component 16, andseals 70 can all be replaced when they are no longer efficient as aresult of wear and use. Replacement of these items on the cyclonicdebris evacuation apparatus 10 or 100 can be much more cost efficientoverall as opposed to replacing an entire pump plunger system, as wouldbe required with prior art pump plunger systems.

When incorporating the modified ring component 16A of FIGS. 51-59 intothe cyclonic debris evacuation apparatus 10, solids can be preventedfrom passing twice over the cup component 14 to reduce its wear and keepthe cup component 14 from premature failure. The removal of the solidscan take place on the same upstroke and downstroke described above. Onthe upstroke, the solids can pass the cup component 14 as it wears andsettles atop the ring component 16A. The ring component 16A can have ataper groove that captures the solids keeping them off the barrel whichcould cause barrel wear.

On the down stroke of the pump, and with the addition of the groove 162and ports 160 in the ring component 16A, solids can be accumulated awayfrom the barrel wall allowing them to escape inward thru the ports 160where they can flow into the interior flow section of the main body. Thesolids can be swept away into the flow keeping the cup component 14,barrel, and plunger from additional wear.

The foregoing description is provided to enable any person skilled inthe relevant art to practice the various embodiments described herein.Various modifications to these embodiments will be readily apparent tothose skilled in the relevant art, and generic principles defined hereincan be applied to other embodiments. Thus, the claims are not intendedto be limited to the embodiments shown and described herein, but are tobe accorded the full scope consistent with the language of the claims,wherein reference to an element in the singular is not intended to mean“one and only one” unless specifically stated, but rather “one or more.”All structural and functional equivalents to the elements of the variousembodiments described throughout this disclosure that are known or latercome to be known to those of ordinary skill in the relevant art areexpressly incorporated herein by reference and intended to beencompassed by the claims. Moreover, nothing disclosed herein isintended to be dedicated to the public regardless of whether suchdisclosure is explicitly recited in the claims.

What is claimed is:
 1. A cyclonic debris evacuation apparatuscomprising: a cyclone component having at least one flute; a cupcomponent fitted over a portion of said cyclone component; a ringcomponent connected to said cup component fitted over a portion of saidcyclone component and having a groove with at least one port, whereinsaid groove extends around a circumference of said ring component; and aring coupler component connected to said ring component and coupled tosaid cyclone component.
 2. The cyclonic debris evacuation apparatus ofclaim 1, wherein the cyclone component has a first plurality of flutespositioned longitudinally along a first end of the cyclone component anda second plurality of flutes positioned longitudinally along a secondend of the cyclone component.
 3. The cyclonic debris evacuationapparatus of claim 1, comprising two or more ports on said groove spacedequidistant from each other.
 4. The cyclonic debris evacuation apparatusof claim 1, wherein said at least one port comprises angled apertures.5. The cyclonic debris evacuation apparatus of claim 1, wherein said atleast one port is connected to a channel formed within said cyclonecomponent.
 6. The cyclonic debris evacuation apparatus of claim 1,wherein said groove tapers inwardly slightly below an outer diameter ofsaid cup component.
 7. The cyclonic debris evacuation apparatus of claim6, wherein said groove comprises a secondary undercut portion havingsaid at least one port formed thereon.
 8. The cyclonic debris evacuationapparatus of claim 1, wherein said cyclone component is connected to asucker rod.
 9. The cyclonic debris evacuation apparatus of claim 1,wherein said ring coupler is connected to a pump plunger.
 10. A debrisremoval apparatus comprising: a hollow valve rod coupler component; acup component fitted over a portion of said hollow valve rod couplercomponent; a ring component fitted over a portion of said hollow valverod coupler component having at least one port, a groove extends arounda circumference of said ring component; a ring coupler component coupledto said hollow valve rod coupler component; and a channel that extendsthrough said hollow valve rod coupler component and said ring couplercomponent and in fluid communication with said at least one port. 11.The debris removal apparatus of claim 10, wherein said groove positionedon an outer diameter of said ring component.
 12. The debris removalapparatus of claim 11, wherein said groove comprises a tapered edge. 13.The debris removal apparatus of claim 11, wherein said groove comprisessaid at least one port in fluid communication with said channel.
 14. Thedebris removal apparatus of claim 10, wherein said hollow valve rodcoupler component comprises at least one flute.
 15. The debris removalapparatus of claim 10, wherein said ring component fitted over a portionof said hollow valve rod coupler component comprises three equidistantports positioned around an outer diameter of said ring component.
 16. Acyclonic debris evacuation apparatus for a tubing pump systemcomprising: a cyclone component having at least one flute and a solidtop plunger adapter for receiving a sucker rod; a cup component fittedover a portion of said cyclone component; a ring component connected tosaid cup component fitted over a portion of said cyclone component andhaving a tapered groove with at least one port; and a ring couplercomponent connected to said ring component and coupled to said cyclonecomponent.
 17. The cyclonic debris evacuation apparatus of claim 16,wherein said solid top plunger adapter comprise external threading. 18.The cyclonic debris evacuation apparatus of claim 16, wherein said solidtop plunger adapter comprises a locking mechanism.